Industrial door assembly and method of assembling same

ABSTRACT

An industrial door assembly is disclosed comprising a rigid internal frame having first and second sides; a door capping attached to edges of the rigid internal frame, the door capping providing generally parallel faces generally parallel to the first and second sides; side panels attached to the generally parallel faces of the door capping generally parallel to the first and second sides of the rigid internal frame; and synthetic insulating material injected within the rigid internal frame and bonding the side panels together. A method of assembling this industrial door assembly is also disclosed.

FIELD OF THE INVENTION

[0001] The present invention relates to industrial doors, and more particularly to insulated doors for use in industrial and retail settings.

BACKGROUND OF THE INVENTION

[0002] In certain industrial and retail settings, such as supermarket stockrooms or the storerooms of the pharmaceutical and food processing industries, it is desirable to provide access doors that are designed for increased strength and enhanced insulating ability.

[0003] A standard industrial door used in such settings comprises a section of solid synthetic foam material with insulating properties, to which material two side panels are glued. However, this industrial door assembly is inherently weak, there being no bonded strength or internal strengthening frame.

[0004] Prior attempts to address this problem include U.S. Pat. No. 5,655,351 to Pohl, et al., which discloses a reinforced refrigerator door assembly. The reinforcement is in the form of cross brace members running diagonally within the door, thereby providing added strength. However, the door uses a door shell of set dimensions, limiting the usefulness of this invention in the context of industrial doors, which doors must be and are designed to various dimensions as required for different applications and settings.

[0005] Another standard insulated door currently on the market employs two pieces of free-floating internal steel to prevent warping of the door, but the shell is again of a one-piece moulded construction. It is easily damaged, and again does not lend itself to the varied door dimensions required by the industry.

SUMMARY OF THE INVENTION

[0006] According to one aspect of the present invention there is provided an industrial door assembly comprising:

[0007] a rigid internal frame having first and second sides;

[0008] a door capping attached to edges of the rigid internal frame, the door capping providing generally parallel faces generally parallel to the first and second sides;

[0009] side panels attached to the generally parallel faces of the door capping generally parallel to the first and second sides of the rigid internal frame; and

[0010] synthetic insulating material injected within the rigid internal frame and bonding the side panels together.

[0011] In exemplary embodiments of this first aspect of the present invention, the rigid internal frame may be composed of steel tubing for enhanced strength, and steel gussets may be added to inside corners to further enhance the structural strength. The door capping is preferably a synthetic material extrusion, most preferably a PVC extrusion, and the side panels are preferably but not necessarily ABS sheeting or stainless steel sheeting. The synthetic insulating material is preferably urethane foam insulation, but it may be any synthetic insulating material that has insulating properties and can strongly bond to the side panels, and it is preferably an expanding foam material that can expand to fill the available space. The rigid internal frame and door capping preferably comprise vent holes to allow air within the rigid internal frame to escape in response to injection of the synthetic insulating material. The door capping preferably comprises receiving means for receiving door hardware and synthetic gaskets.

[0012] According to a second aspect of the present invention there is provided a door capping for use with an industrial door, the industrial door having a rigid internal frame and side panels, the door capping comprising:

[0013] an elongate core body; and

[0014] two generally parallel flanges attached to the elongate core body extending along a length of the core body, the elongate core body and two generally parallel flanges forming a receiving channel for slidably receiving an edge of the rigid internal frame, the two generally parallel flanges providing generally parallel faces to which the side panels can be attached.

[0015] In exemplary embodiments of this second aspect of the present invention, the core body comprises receiving means for receiving door hardware and synthetic gaskets, and the door capping is preferably a synthetic material extrusion, most preferably a PVC extrusion. This door capping can be used in the industrial door assembly of the first aspect of the present invention.

[0016] According to a third aspect of the present invention there is provided a method of assembling the industrial door assembly of the first aspect of the present invention comprising the steps of:

[0017] (a) assembling the rigid internal frame;

[0018] (b) attaching the door capping to the rigid internal frame;

[0019] (c) bonding the side panels to the generally parallel faces of the door capping;

[0020] (d) providing an access means through the door capping and rigid internal frame to an inner space defined by the rigid internal frame and side panels; and

[0021] (e) injecting the synthetic insulating material through the access means into the inner space, the synthetic insulating material bonding to the side panels.

[0022] In exemplary embodiments of this third aspect of the present invention, the rigid internal frame can be composed of steel tubing and the assembling step (a) involves welding. The attaching step (b) preferably but not necessarily involves mechanical fastening of the door capping to the rigid internal frame, and the access means of step (d) can be at least one hole drilled through the door capping and rigid internal frame. The bonding of step (c) is preferably a chemical bonding. A final step is preferably included wherein the door capping comprises receiving means for receiving door hardware and synthetic gaskets, the method further comprising the final step of inserting hardware and synthetic gaskets into the receiving means. Where, in preferred embodiments, the synthetic insulating material is an expanding foam material, step (e) would be followed by a final step allowing the synthetic insulating material to expand. Where, in preferred embodiments, the rigid internal frame and door capping comprise vent holes to allow air within the rigid internal frame to escape in response to injection of the synthetic insulating material, the method further comprises the final step of allowing air to escape from the rigid internal frame through the vent holes in response to injection of the synthetic insulating material.

[0023] The present invention accordingly provides an industrial door assembly that has enhanced strength and insulating ability, while providing greater flexibility in terms of possible door dimensions, in that the rigid internal frame can be designed to any desired dimensions while the door capping enables foam injection to bind the assembly together.

[0024] A detailed description of an exemplary embodiment of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as limited to this embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In the accompanying drawings, which illustrate an exemplary embodiment of the present invention:

[0026]FIG. 1 is a cross-sectional view along line 1-1 of FIG. 2B;

[0027]FIG. 2A is a front elevational view of the industrial door assembly without the side panels or synthetic insulating material;

[0028]FIG. 2B is a front elevational view of the fully-assembled industrial door assembly;

[0029]FIG. 3A is a detailed end view of a synthetic gasket used in single-door applications;

[0030]FIG. 3B is a detailed end view of a synthetic gasket used in double-door applications; and

[0031]FIG. 4 is a perspective view of a length of the door capping.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

[0032] Referring now in detail to the accompanying drawings, there is illustrated an industrial door assembly according to the present invention, generally referred to by the numeral 10. As can best be seen in FIGS. 1, 2A, and 2B, the exemplary embodiment of the industrial door assembly 10 comprises a rigid internal frame 12 having first and second sides 14, the rigid internal frame 12 being of steel tubing in this embodiment and welded together, and a door capping 16 attached to edges 18 of the rigid internal frame 12, the door capping 16 providing generally parallel faces 20 which are generally parallel to the first and second sides 14. The rigid internal frame 12 comprises steel gussets 30 in every inside corner to strengthen the industrial door assembly 10 and help prevent premature delamination. The industrial door assembly 10 further comprises side panels 22 which are attached to the generally parallel faces 20 of the door capping 16 in an orientation generally parallel to the first and second sides 14 of the rigid internal frame 12. The hollow structure thus formed is filled, in the manner set out in the following description, with a synthetic insulating material 24, specifically a urethane foam insulation in the exemplary embodiment, which acts to bond the side panels 22 together and thus strengthens the industrial door assembly 10. The synthetic insulating material 24 is preferably an expanding foam that can expand after injection to fill the hollow structure.

[0033] The door capping 16 in the exemplary embodiment is a synthetic material extrusion, specifically a PVC extrusion. Referring to FIGS. 1 and 4, the door capping 16 comprises an elongate core body 32 from which extend two generally parallel flanges 34, the generally parallel flanges 34 being either attached to or formed as a unity with the elongate core body 32, the generally parallel flanges 34 being oriented along the long axis of the elongate core body 32. The elongate core body 32 and the two generally parallel flanges 34 form a receiving channel 36 for slideably receiving the edge 18 of the rigid internal frame 12, and the two generally parallel flanges 34 provide the two generally parallel faces 20 to which the side panels 22 are attached. The door capping 16 further comprises receiving means 26 for receiving any desired door hardware (not shown) or synthetic gaskets 28 a,b. Two common designs of synthetic gaskets 28 a,b are illustrated in FIGS. 3A and 3B; the synthetic gasket 28 a of FIG. 3A is used with single-door applications, while the synthetic gasket 28 b of FIG. 3B is used with double-door applications.

[0034] The side panels 22 can be composed of diverse materials, but are preferably composed of ABS sheeting, which adhere to the generally parallel faces 20 of the door capping 16 and bond with the synthetic insulating material 24 when injected. The side panels 22 can also be composed of stainless steel sheeting, which is desirable in many industrial and retail contexts. The side panels 22 are preferably of the same width as a recess 42 in the door capping 16, as can be seen in FIG. 1, allowing for a smooth surface continuity between the side panels 22 and the door capping 16.

[0035] In the preferred method of assembling the industrial door assembly 10, the first step is to weld steel tubing together to form the rigid internal frame 12 to desired specifications, along with steel gussets 30 welded in all inside corners. Then, the door capping 16 is attached to the rigid internal frame 12, preferably by mechanical fastening means. The side panels 22 can then be bonded to the generally parallel faces 20 of the door capping 16, preferably by a chemical bonding. As can be seen in FIG. 2A, an access means 38 is provided, in this exemplary case a simple drilled hole, through the door capping 16 and the rigid internal frame 12, into an inner space (not numbered) defined by the rigid internal frame 12 and side panels 22. More than one hole may be required for the access means 38 to be adequate in a given context. The synthetic insulating material 24 is then injected through the access means 38 into and filling this inner space, such that it bonds to the side panels 22 and provides a firm, strong structure. To enable air within the inner space to escape in response to injection of the synthetic insulating material 24, a vent hole 40 is provided through the door capping 16 and the rigid internal frame 12, although more than one vent hole 40 may be required. Finally, any door hardware (not shown) or synthetic gaskets 28 a,b can be fitted within the receiving means 26 as desired. Window openings (not shown) can also be cut out of the industrial door assembly 10 once the synthetic insulating material 24 hardens after injection, and windows (not shown) inserted therein.

[0036] The utility of the present invention resides in its usefulness in industrial and retail settings which require strong, insulated doors of various desired dimensions and designs. The present invention addresses this need.

[0037] While a particular embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention and are intended to be included herein. It will be clear to any person skilled in the art that modifications of and adjustments to this invention, not shown, are possible without departing from the spirit of the invention as demonstrated through the exemplary embodiment. For example, the generally parallel flanges 34 may not be necessary if the core body 32 itself can be designed to directly accept the side panels 22 and be firmly attached to the rigid internal frame 12. The invention is therefore to be considered limited solely by the scope of the appended claims. 

Embodiments of the Invention in Which an Exclusive Property or Privilege is claimed are Defined as Follows:
 1. An industrial door assembly comprising: a rigid internal frame having first and second sides; a door capping attached to edges of the rigid internal frame, the door capping providing generally parallel faces,generally parallel to the first and second sides; side panels attached to the generally parallel faces of the door capping generally parallel to the first and second sides of the rigid internal frame; and synthetic insulating material injected within the rigid internal frame and bonding the side panels together.
 2. The industrial door assembly of claim 1 wherein the rigid internal frame is composed of steel tubing.
 3. The industrial door assembly of claim 1 wherein the door capping is a synthetic material extrusion.
 4. The industrial door assembly of claim 3 wherein the door capping is a PVC extrusion.
 5. The industrial door assembly of claim 1 wherein the side panels are ABS sheeting.
 6. The industrial door assembly of claim 1 wherein the side panels are stainless steel sheeting.
 7. The industrial door assembly of claim 1 wherein the synthetic insulating material is a urethane foam insulation.
 8. The industrial door assembly of claim 1 wherein the synthetic insulating material is an expanding foam material.
 9. The industrial door assembly of claim 1 wherein the rigid internal frame and door capping comprise vent holes to allow air within the rigid internal frame to escape in response to injection of the synthetic insulating material.
 10. The industrial door assembly of claim 1 wherein the door capping comprises receiving means for receiving door hardware and synthetic gaskets.
 11. The industrial door assembly of claim 2 wherein the rigid internal frame comprises steel gussets.
 12. A door capping for use with an industrial door, the industrial door having a rigid internal frame and side panels, the door capping comprising: an elongate core body; and two generally parallel flanges attached to the elongate core body extending along a length of the core body, the elongate core body and two generally parallel flanges forming a receiving channel for slideably receiving an edge of the rigid internal frame, the two generally parallel flanges providing generally parallel faces to which the side panels can be attached.
 13. The door capping of claim 12 wherein the core body comprises receiving means for receiving door hardware and synthetic gaskets.
 14. The door capping of claim 12 wherein the door capping is a synthetic material extrusion.
 15. The door capping of claim 12 wherein the door capping is a PVC extrusion.
 16. The industrial door assembly of claim 1 wherein the door capping comprises: an elongate core body; and two generally parallel flanges attached to the elongate core body extending along a length of the core body, the elongate core body and two generally parallel flanges forming a receiving channel for slidably receiving an edge of the rigid internal frame, the two generally parallel flanges providing generally parallel faces to which the side panels can be attached.
 17. A method of assembling the industrial door assembly of claim 1 comprising the steps of: (a) assembling the rigid internal frame; (b) attaching the door capping to the rigid internal frame; (c) bonding the side panels to the generally parallel faces of the door capping; (d) providing an access means through the door capping and rigid internal frame to an inner space defined by the rigid internal frame and side panels; and (e) injecting the synthetic insulating material through the access means into the inner space, the synthetic insulating material bonding to the side panels.
 18. The method of claim 17 wherein the rigid internal frame is composed of steel tubing and is assembled by welding.
 19. The method of claim 17 wherein the door capping is mechanically fastened to the rigid internal frame.
 20. The method of claim 17 wherein the access means are at least one hole drilled through the door capping and rigid internal frame.
 21. The method of claim 17 wherein the bonding of the side panels to the generally parallel faces of the door capping is a chemical bonding.
 22. The method of claim 17 wherein the door capping comprises receiving means for receiving door hardware and synthetic gaskets, the method further comprising the final step of inserting hardware and synthetic gaskets into the receiving means.
 23. The method of claim 17 wherein the synthetic insulating material is an expanding foam material, the method further comprising the final step of allowing the synthetic insulating material to expand.
 24. The method of claim 17 wherein the rigid internal frame and door capping comprise vent holes to allow air within the rigid internal frame to escape in response to injection of the synthetic insulating material, the method further comprising the final step of allowing air to escape from the rigid internal frame through the vent holes in response to injection of the synthetic insulating material. 